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FUTERA FUSION INSTALLATION AND OPERATION INSTRUCTIONS

3

RATINGS & CAPACITIES

 

Before undertaking the installation of the Futera Series 
boiler/water heater check the rating plate to ensure that 
the unit has been sized properly for the job. The “Net I=B=R 
Ratings” specify the equivalent amount of direct copper 
radiation that the unit can supply under normal conditions. 
Also ensure that the unit has been set up for the type of 
gas available at the installation site. Other important 
considerations are the availability of an adequate electrical 
supply, fresh air for combustion and a suitable chimney or 
vent system.

BOILER/WATER HEATER LOCATION

 

1.    This boiler/water heater is suitable for indoor and oudooor 

installations. Locate the boiler/water heater in an area 
that provides good access to the unit. Servicing may 
require the removal of jacket panels. Allow the minimum 
clearances between adjacent construction and the 
boiler/water heater as listed in Table 1. 

NOTE: Service clearances are not mandatory, but are 
recommended to ensure ease of service should it be 
required.

Table 1 
 

Clearance to  

  Service

 Combustibles 

 

Clearance

   

in 

mm

 in 

mm

Top 

6

  

153

 

30

  

762

Back 

6

 

153

 

24

  

610

Left Side 

6

 

153

 

24

  

610

Right Side 

6

  

153

 

24

 

610

Front 

6

 

153

 

30

 

762

2.   An optimum site will be level, central to the piping 

system, close to a chimney or outside wall and have 
adequate fresh air for combustion. Ensure that the 
boiler/water heater is level from front to back and from 
side to side. Use metal shims to level the boiler/water 
heater. Electrical and electronic components must also 
be protected from exposure to water during operation 
and maintenance. DO NOT install this boiler/water 
heater in a location that would subject any of the gas 
ignition components to direct contact with water or 
excessive moisture during operation or servicing. 

3.   Ensure that the fl oor is structurally sound and will 

support the weight of the boiler/water heater.

NOTE: The Futera may be installed directly on combus-
tible fl ooring, but never on carpeting.

4.   Locate the boiler/water heater in an area that will 

prevent water damage to adjacent construction should 
a leak occur or during routine maintenance.  If such 
a location doesn’t exist, a suitable drain pan that’s 
adequately drained must be installed under the unit.

5.   DO NOT place this boiler/water heater in a location that 

would restrict the introduction of combustion air into 
the unit or subject it to a negative pressure, see 
“GENERAL VENTING GUIDELINES”.

6.   NEVER place this boiler/water heater in a location that 

would subject it to temperatures at or near freezing, 
see the “FREEZE PROTECTION” section on page 12.

WARNING: Never store combustible materials, 
gasoline or any product containing flammable 
vapors or liquids in the vicinity of the boiler/water 
heater. Failure to comply with this warning can 
result in an explosion or fire causing extensive 
property damage, severe personal injury or death!

COMBUSTION AIR & VENTILATION

WARNING: This boiler/water heater must be 
supplied with combustion air in accordance with 
Section 5.3, Air for Combustion & Ventilation, of the 
latest revision of the National Fuel Gas Code, ANSI 
Z223.1/NFPA 54 and all applicable local building 
codes. Canadian installations must comply with 
CAN/ CGA B149.1 or .2 Installation Code for Gas 
Burning Appliances and Equipment, or applicable 
provisions of the local building codes. Failure to 
provide adequate combustion air for this boiler/
water heater can result in excessive levels of 
carbon monoxide which can result in severe 
personal injury or death!

To operate properly and safely this boiler/water heater 
requires a continuous supply of air for combustion. NEVER 
store objects on or around the boiler/water heater!

CAUTION: Combustion air contaminated with 
fl uorocarbons or other halogenated compounds such 
as cleaning solvents and refrigerants will result in the 
formation of acids in the combustion chamber. These 
acids will cause premature failure of the boiler/water 
heater voiding the warranty!

CAUTION: If the boiler/water heater is operated while 
the building is under construction it MUST be 
protected from wood, concrete, sheet rock and other 
types of dust. Failure to properly protect the unit from 
construction dust will damage the unit voiding the 
warranty!

Buildings will require the installation of a fresh air duct or 
other means of providing make-up air if the intake air option 
isn’t used. Any building utilizing other gas burning 
appliances, a fi replace, wood stove or any type of exhaust 
fan must be checked for adequate combustion air when all 
of these devices are in operation at one time. Sizing of an 
outside air duct must be done to meet the requirements 
of all such devices.

WARNING: Never operate the Futera in an 
environment subjected to a negative pressure 
unless it is Direct Vented.  Failure to comply with 
this warning can result in excessive levels of 
carbon monoxide causing severe personal injury 
or death!

Содержание FUTERA FUSION Series

Страница 1: ...Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or any other appliance WHAT TO DO IF YOU SMELL GAS Do not try to light any appliance Do not touch any electri...

Страница 2: ...vice des incendies L installation et l entretien doivent tre assur s par un installateur ou un service d entretien qualifi ou par le fournisseur de gaz The Futera Series finned copper heating boiler w...

Страница 3: ...ction of combustion air into the unit or subject it to a negative pressure see GENERAL VENTING GUIDELINES 6 NEVER place this boiler water heater in a location that would subject it to temperatures at...

Страница 4: ...given to the blockage effects of louvers grills and screens Screens must have a minimum mesh size of 1 4 in 6 4 mm If the free area through a louver or grill is not known ducts should be sized per Ta...

Страница 5: ...tems must be fully supported by the building structure and not by the boiler water heater Appropriate thimbles and fire stops must be used where required WARNING Common vent systems must be properly e...

Страница 6: ...04 C Horizontal vent systems shall terminate at least 4 ft 1 2 m below 4 ft 1 2 m horizontally from or 1 ft 0 30 m above any door window or gravity air inlet into any building It must not terminate le...

Страница 7: ...e same plane outside wall in order to prevent pressure differences due to prevailing winds In cold climates double wall or insulated inlet pipe recommended to prevent condensation 5 FT 1 5 m 1 5 FT 0...

Страница 8: ...3 Vertical Air Intake and Venting for Direct Vent System Note Locate exhaust terminal downwind to reduce flue gas recirculation Figure 4 Combination Direct Vent Systems 10 FT 3 1 m 4 FT 1 2 m 5 FT 1 5...

Страница 9: ...r combustion is taken from the space in which the unit is installed The applicable instructions under the COMBUSTION AIR VENTILATION section must be followed The vent guidelines under the Horizontal D...

Страница 10: ...ndraft The unit s shouild be located at least 3 ft 1 m from structures Outdoor installations are not recommended in areas where the danger of snow blockage exists CAUTION Do not place the boiler water...

Страница 11: ...l any type of valve between the boiler water heater and the relief valve or an explosion causing extensive property damage severe personal injury or death may occur Flow Switch The flow switch supplie...

Страница 12: ...igure 8 Futera Fusion Piping Air Vent Aquastat Union Automatic Thermometer Flow Switch Pressure Relief Valve Reducing Valve Check Valve Pressure Pump Valve Balance Valve Vacuum Relief Valve Temperatur...

Страница 13: ...lve and piping Low Water Cutoff If a boiler is installed above any radiation elements it must be fitted with a low water cutoff device Refer to the wiring diagram supplied with the boiler water heater...

Страница 14: ...ated on pump flange On multiple boiler installations the flow switch may fail due to trapped air See manual for procedure 3 All boilers furnished with factory mounted outlet water temperature gauge No...

Страница 15: ...flange On multiple boiler installations the flow switch may fail due to trapped air See manual for procedure 4 All boilers furnished with factory mounted outlet water temperature gauge 5 Condensate l...

Страница 16: ...ugh a Futera Fusion water heater is 97 GPM 6 1 L s on 500 through 1000 models and 136 GPM 8 9 L s for 1250 through 2000 models The cupro nickel heat exchanger allows for 108 GPM 6 8 L s on 500 through...

Страница 17: ...xchanger Selection Graph To properly size the pump a grain hardness and pH test must be taken at the installation site before the order is placed Proper pump sizing will improve heater performance and...

Страница 18: ...with a combination temperature pressure relief valve 6 MA Code requires an 1 8 hole in check valve to compensate for thermal expansion 7 Use balance valve to set the temperature rise through the boile...

Страница 19: ...bination temperature pressure relief valve 6 MA Code requires an 1 8 hole in check valve to compensate for thermal expansion 7 Use balance valve to set the temperature rise through the boiler Delta T...

Страница 20: ...your RBI representative to resolve the problem NOTE A minimum gas supply pressure of 2 in 51 mm W C natural or propane and maximum 14 in 356 mm W C natural or propane must be available at the safety...

Страница 21: ...outdoors The wire size must be compatible with the total amp draw of the circuit Refer to the wiring diagram supplied with the boiler water heater for proper wiring connections GENERAL OPERATION WARN...

Страница 22: ...r Si vous ne pouvez rejoindre le fournisseur appelez le service de incendies C Do not use this appliance if any part has been under water Immediately call a qualified service technician to inspect the...

Страница 23: ...ttle out for a few minutes and observe the combustion reading Refer to Combustion Reading table for proper combustion readings and elbow pressure Table 12 The low fire O2 CO2 can be adjusted in the fi...

Страница 24: ...electric power to the boiler if service is to be performed 3 Close the manual main and pilot gas shut off valves COMMENT COUPER L ADMISSION DE GAZ DE L APAREIL 1 R glez le thermostat la temp rature l...

Страница 25: ...els of carbon monoxide or an explosion resulting in severe personal injury or death Required Gas Pressure Provide gas supply pressure at inlet to boiler gas train as follows LP Nat Minimum in W C 2 2...

Страница 26: ...ork For all other member boilers the dip switches will remain in the off position Dip switches J3 and J6 need to be placed in the on position to terminate a modbus communication network when used 2 0...

Страница 27: ...be used to control HeatNet equipped boilers Method 1 A 4 20mA signal can be used to directly modulate each boiler from a remote panel or building management system On multiple boiler installations th...

Страница 28: ...ithout adequate water flow through the heat exchanger DIAGNOSTICS TheFuteraFusionhasadisplaythatindicatesthesequenceof operation The display will also list faults should the unit fail to operate An ex...

Страница 29: ...ET 160 F GAS PRESSURE INTERLOCK SPARE 4 This is also a spare interlock similar to INTERLOCK SPARE 3 for future expansion or use as a field interlock The interlock is located on J11B SPARE 4 FAULT SYST...

Страница 30: ...If the open sensor fault is displayed the sensor in the position reported was originally detected but has since opened The boiler will shut down on any OPEN sensor FAULT SYSTEM SET 160 F OPEN OUTSIDE...

Страница 31: ...rner together from the boiler water heater taking care not to damage the spark rods and or their alignment 8 Disconnect the compression nut from the inside of the transition piece 9 Remove the transit...

Страница 32: ...and CHECKING AND ADJUSTMENTS sections of this manual for reference 1 Check the operating controls for proper operation 2 A float type low water cutoff device must be flushed out per the manufacturers...

Страница 33: ...Last limit in the Limit String to Ignition Control Have We received the BLOWER signal CALL FOR HEAT PRE_PURGE Interlocks OK Are we below the Temp Band YES fire the boiler NO Send 120 VAC BLOWER signa...

Страница 34: ...J11B to identify which interlock has tripped Reset the Interlock or check for disconnected wiring or shorts The Air Pressure from UV Sensor interlock if displayed will allow the boiler to function but...

Страница 35: ...rts SEE VIEW A SEE VIEW B 15B 15A 41 32 36 57 46 13 35 40 33 31 23 27 60A 24 62 28 47 39 15 SEE VIEW C 38 37 25 67 66 62 65 30 63 43 42 60 14 29 64 33 45 68 69 10 4 11 75 12 5 2 7 74 1 73 71 12 8 70 1...

Страница 36: ...FUTERA FUSION INSTALLATION AND OPERATION INSTRUCTIONS 36 VIEW B ROTATE D VIEW 16 18 VIEW A VIEW C RIOM 74 REV A 77 54 54A RIOM 74 REV A RIOM 74 REV A...

Страница 37: ...3 1 1 1 70 2344 1 1 1 1 15 Burner Pilot Orifice Assembly 70 2529 1 70 2530 1 70 2531 1 70 2532 1 70 2533 1 70 2534 1 70 2535 1 15a Transition Gasket 06 0026 1 1 1 06 0027 1 1 1 1 15b Burner Gasket 06...

Страница 38: ...ear Panel 70 2414 1 1 1 70 2415 1 1 1 1 29 Rear Pipe Enclosure Assembly 70 2333 1 1 1 70 2334 1 1 1 1 30 Lower Rear Jacket Panel 03 3111 1 03 3112 1 03 3113 1 03 3114 1 03 3115 1 03 3116 1 03 3117 1 3...

Страница 39: ...ly CW 70 2563 1 1 1 70 2564 1 1 1 1 42 Air Filter 09 0489 1 1 1 09 0498 1 1 09 0499 1 1 44 Pilot Tube Assembly 70 9024 1 1 1 70 9024 1 1 1 70 9025 1 1 NS Pilot Train Assembly NG 70 9026 1 1 1 1 1 1 1...

Страница 40: ...1 1 1 1 1 NS Terminal Block 6P 48 0157 1 1 1 1 1 1 1 NS Terminal Block 4P 48 0161 1 1 1 1 1 1 1 NS Resistor Assembly 70 9001 1 1 1 1 1 1 1 NS Mini Peeper C7027A 16 0009 1 1 1 1 1 1 1 NS UV Amplifier...

Страница 41: ...2 2 2 2 2 2 2 74 Bottom Horizontal Frame Extension Profile 04 1072 2 2 2 04 1070 2 2 2 2 75 Vertical Center Extension Profile 04 1062 2 04 1063 2 04 1064 2 04 1065 2 04 1066 2 04 1067 2 04 1068 2 76 F...

Страница 42: ...board Also locate the gas pressure tapping upstream of the main gas valve 1 Cycle boiler and hold at trial for pilot ignition 2 Set pressure to 2 2 5 W C Flame signal should read 5 0 V DC 3 Cycle boil...

Страница 43: ...OMER COMMISSIONED BY _____________________________ SIGNATURE DATE ___________________ THE DELTA T BETWEEN THE HEATERS INLET AND OUTLET IS CRITICAL TO PROPER FLOW BEFORE YOU LEAVE THE JOBSITE YOU MUST...

Страница 44: ...t OA Setpoints Water Temp At High OA Temp Water Temp At Low OA Temp PUMP OPTIONS System Pump Post Purge Time Always Enabled Summer Pump Jog Local Pump Delta Temp Enab Delta Temp Post Prge Time s Alway...

Страница 45: ...ol H Net Master Local Address Console Address Modular Boiler Set Add Boiler Delay Shed Boiler Delay Modulate Delay Time Mod Max Last Fire Stop Band Offseet Boiler Start Time Modulation PID P roportion...

Страница 46: ...side wall horizontally vented gas fueled equipment is installed in a crawl space or an attic the hard wired carbon monoxide detector with alarm and battery back up may be installed on the next adjace...

Страница 47: ...instructions for the installation of the venting system design or the venting system components and 2 A complete parts list for the venting system design or venting system d MANUFACTURER REQUIREMENTS...

Страница 48: ...ult of the equipment and is not covered under the manufacturer s warranty Excessive pitting and erosion on the inside of the heat exchanger tubes caused by high water velocity through the tubes and is...

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